Multiple candle wick assemblies and methods and appartus for making the same

Abstract

Apparatus for making wax-coated candle wick assemblies are provided within include a wax applicator sized and configured to receive therein a multiple candle wick construction having first and second spaced apart candle wicks and a ladder filament connected to and extending back and forth between the first and second candle wicks so as to establish respective crossing portions that are spaced apart from one another along a lengthwise direction of the wick construction. A forming device is positioned relative to the inlet of the wax applicator channel to assist in folding the candle wick construction about a longitudinal axis thereof and into a generally U-shaped configuration such that conveyance of the candle wick construction through the wax applicator will sequentially fold the candle wick construction into such U-shaped configuration and maintain such U-shaped configuration by the application of wax thereon.

What is claimed is: 
     
       1. An apparatus for making a wax-coated candle wick assembly comprising:
 a wax applicator which includes a wax applicator channel having an inlet and an outlet, the wax applicator channel being sized and configured to receive therein a multiple candle wick construction having first and second spaced apart candle wicks and a ladder filament connected to and extending back and forth between the first and second candle wicks so as to establish respective crossing portions that are spaced apart from one another along a lengthwise direction of the wick construction; 
 a forming device positioned relative to the inlet of the wax applicator channel which is sized and configured to assist in folding the candle wick construction about a longitudinal axis thereof and into a generally U-shaped configuration; and 
 a conveyance system which conveys the candle wick construction sequentially into the inlet of the wax applicator channel in operative association with the forming device to thereby cause the crossing portions of the ladder filament to be folded about the longitudinal axis of the candle wick construction and into the generally U-shaped configuration, and then through the applicator channel to allow a wax sheath to be applied therein onto the candle wicks and crossing portions of the ladder filament to thereby maintain the candle wick construction in the generally U-shaped configuration thereof so as to obtain the candle wick assembly. 
 
     
     
       2. The apparatus according to  claim 1 , wherein forming device comprises a longitudinally oriented fixed-position forming mandrel, wherein the candle wick assembly may be folded about the forming mandrel and assume the generally U-shaped configuration. 
     
     
       3. The apparatus according to  claim 2 , wherein the fixed-position forming mandrel is a fixed-position wire, rod or plate positioned at least partly within the wax applicator channel. 
     
     
       4. The apparatus according to  claim 1 , wherein the forming device comprises a forming die positioned at the inlet of the wax applicator channel to cause the candle wick construction to be folded about the longitudinal axis thereof into the generally U-shaped configuration. 
     
     
       5. The apparatus according to  claim 1 , wherein the forming device comprises a wax filament that is capable of being introduced into the inlet of the wax applicator channel simultaneously with the candle wick construction, wherein the candle wick construction is capable of being folded about the wax filament into the generally U-shaped configuration thereof. 
     
     
       6. The apparatus according to  claim 1 , wherein the forming device comprises a stationary forming wire having a positionally fixed proximal end, the forming wire extending from the proximal end through the inlet of the wax applicator channel so as to terminate a predetermined distance at a free distal end thereof within the applicator channel. 
     
     
       7. The apparatus according to  claim 1 , further comprising a spool having wound thereon a supply of the candle wick construction in a substantially flat configuration. 
     
     
       8. The apparatus according to  claim 1 , wherein the wax applicator further includes an outlet forming die having an outlet orifice. 
     
     
       9. The apparatus according to  claim 1 , further comprising a cooling system downstream of the outlet of the wax applicator channel so as to cool the wax sheath and maintain the candle wick assembly in the generally U-shaped configuration thereof. 
     
     
       10. The apparatus according to  claim 9 , wherein the conveyance system comprises a product spool downstream of the cooling system for taking up the wax-coated candle wick assembly, and a drive motor for driving the product spool to wind the wax-coated candle wick assembly onto the product spool and cause conveyance of the multiple candle wick construction through the applicator channel of the wax applicator and downstream cooling system. 
     
     
       11. The apparatus according to  claim 10  which further comprises a second wax applicator and a second cooling system positioned downstream of the first-mentioned cooling system and upstream of the product spool. 
     
     
       12. The apparatus according to  claim 11  wherein the second wax applicator includes second inlet and outlet forming dies each having second inlet and outlet orifices, respectively, to further assist in forming the candle wick assembly into the U-shaped configuration.